Processing device and method



A ril 13, 1965 Filed Feb. 8, 1961 J. R. TURNER ETAL PROCESSING DEVICE AND METHOD 2 Sheets-Sheet 1 JOHN R. TURNER ROBERT J. WILSON INVENTORS BY %MM 0M ATTORNEYS April 13, 1965 J. R. TURNER ETAL PROCESSING DEVICE AND METHOD 2 Sheets-Sheet 2 Filed Feb. 8. 1961 mm m 3 E RMR N w m m JN r s e m m a /N 4 mm M 0 JR W 2 7- v 4.

llllllllllll |I lnlll nlllllllllllllllllLnllll United States Patent 3,177,790 PROCESSING DEVICE AND METHOD John R. Turner and Robert J. Wilson, Rochester, N.Y., assignors to Eastman Kodak Company, Rochester, N.Y., a corporation of New Jersey Filed Feb. 8, 1961, Ser. No. 87,874 7 Claims. (Cl. 95-89) This invention relates generally to photographic processing, and more specifically to an apparatus and method of processing Webs or the like using viscous solutions.

In the continuous conventional tank-type processing machine, it is necessary to transport the sheet or web by means of racks or roller systems through the processing solutions contained in a plurality of tanks arranged m side by side relation for successively totally immersing the sheet or web in each tank. Although a conventional processing machine of this type may operate satisfactorily, it sutfers from the disadvantage of being large and bulky because of the large volume of solutions required. Other disadvantages of the conventional processing machine are: 1) the large volumes of solution used must be kept under close chemical control, (2) large quantifies of chemicals must necessarily be used, (3) special recirculation equipment to provide agitation and keep the solutions well mixed is required, and (4) apparatus for discharging the expended solution and replenishing the solution with fresh chemicals is required. A further disadvantage of the conventional equipment is that even with replenishing apparatus, it is virtually impossible to keep the chemicals in solution in a fresh state. Also, the sheet or web is thoroughly soaked in the processing solutions so that a relatively longer drying time is required to satisfactorily dry the sheet or web. In addition, the total processing time required from the initial introduction of the sheet or Web into the processing machine to the time that it is satisfactorily dried is considerable. The apparatus and method of this invention for the processing of a material by the use of viscous processing solutions is believed to obviate these and other disadvantages of conventional processing equipment.

One of the objects of the present invention is to provide an apparatus and method for the processing of materials with viscous processing solutions that requires a shorter processing time than conventional processing equipment.

Another object of this invention is to provide an apparatus and method for the processing of materials with viscous solutions in which only fresh chemical solutions are used.

Another object of the present invention is to provide an apparatus and method for the processing of materials with viscous solutions in which only the original preparation of the viscous solution requires chemical control.

Still another object of this invention is the provision of an apparatus and method for the processing of materials with viscous solutions that does not require replenishment of solution, recirculation equipment or large volumes of solution.

Another object of the invention is the provision of an apparatus for the processing of materials with viscous solutions that is less bulky, and hence requires less installation space than conventional equipment.

A further object of the invention is to provide an apparatus and method for the processing of materials with viscous solutions in which the results produced are considerably more uniform than those produced by conventional equipment.

. A further object of the invention is to provide an apparatus and method for the processing of material with viscous solutions in which the quantity of chemicals used 3,177,790 Patented Apr. 13, 1965 per unit of processed film area is materially less than that of other machines.

Still another object of this invention is the provision of apparatus and method for the processing of materials with viscous solutions in which the base of the material is not soaked in the process, and hence the material is not aifected by mechanical distortions common to other types of machine processing, and the drying time is eifectively reduced.

The above and other objects and advantages will be apparent from the following description when read in connection with the accompanying drawings, in which:

FIG. 1 is a diagrammatic view in side elevation of a preferred embodiment of a processing machine of this invention; and

FIG. 2 is an enlarged view in perspective of a portion of the processing device of FIG. 1.

With reference to the drawings, a preferred embodiment of a processing device 3 is disclosed for processing a photographic web material 4 such as film or paper. This processing device 3 does not utilize the conventional method of processing in which the photographic material 4 is totally immersed in the processing solution, and passes successively through tanks of processing solution, but rather employs a processing technique in which a layer of viscous processing solution, thickened with an inert agent, is coated on the emulsion surface of the Web 4 of photographic material or the like, in the developing zone. It remains for the duration of the process step, and is then quickly removed. The material 4 is transported to the next processing zone which may entail the application of another coating of viscous solution. Since the layer or coating is in static contact with the emulsion, there is no agitation and all agitation effects are eliminated. The fact that no agitation exists is compensated for by properly balancing the process chemically. In processing of this type, fresh processing solutions are always used so that the usual problems of seasoning, solution control, replenishment and recovery are eliminated.

The processing device of this invention has been used to successfully process Ektacolor Paper and other photographically exposed films and/or papers. This process contemplates the sequential application to the paper of a viscous developer at 100 F. in an atmosphere saturated with water vapor, spraywash at approximately 100 F., stop bath, combination bleach-fix or blix at approximately 96 15., water wash and stabilizing bath. The developer is of the normal type in which a thickening agent is added in an amount required to give the desired viscosity for best results. If this viscosity is too low, the developer may move on the surface producing drag and other undesired effects. If the viscosity is too high, the developer may be difficult to coat in a uniform layer of the desired thickness. The combination bleach-fix or blix is the known Farmers Reducer formed from two solutions, one containing a thiosulfate and the other containing 21 ferricyanide, which are prepared separately and mixed just prior to application to the emulsion surface.

As shown in the drawings, the processing device 3 of this invention comprises a box-like housing 5 having hinged doors 6, as seen best in FIG. 2 which when closed co-operate with housing 5 to form a processing chamber 7 in which the processing equipment is mounted. This processing device 3 is extremely compact, having an overall dimension of approximately 7 feet in height, 4 feet in width, and 2 feet in depth. The requirements of the processing device are simple: a supply of viscous developer; a supply of stop, bleach, fix, and stabilizer solutions; a controllable source of water at 100 to supply about gallons per hour; a drain capable of handling this Water plus the small amounts of processing solu- The web of photographic material 4 to be processed is introduced into processing chamber 7 through an opening 13 therein, and is directed over a pair of fixed freeturning idler rollers, 14, 15 and over another free-turning idler roller 16 mounted on a supply elevator carriage 17 which is slidably movable in a vertical direction on rods 18. The supply elevator carriage 17 is of any well known type adapted to move up or down within limits to take up or'let out web 4 while maintaining relatively constant tension thereon' The web 4 then passes through a guide member 19 having side flanges 21 engaging the edges of web 4, and fixed rods 22 in sliding engagement with'the back of web 4, as seen best in FIG. 2. The web 4 then passes over polished idler rollers 23, 24 which serve to change the direction of web 4, and assure that the web is in engagement with at least 180 of the periphery of a pacer roller 25. The pacer roller 25 is neoprene covered, and guidesweb 4 accurately to a coating hopper 26, and further is driven by a synchronous motor, not shown, through pulleys and a timing belt, not shown, at a speed sufilcient to transport web 4 in this instance at 3 /2 feet per minute. It should be understood that other processing speeds may be used and applicants do not want to be limited to any particular speed. The web 4 as it leaves pacer roller 25 passes between developer coating hopper 26 and a stationary back-up. cylinder 27. The developer coating hopper 26 is a water-jacketed extrusion type hopper which is maintained by the water at a temperature of approximately 100 F. The hopper opening is of a sufiicient length to apply the viscous developer to the full width of web 4, and is further of a width of approximately 0.018 inch for forming a layer of viscous developer of that thickness. The viscous developer is fed to hopper 26 by a commercially available metering pump, not shown. The hopper 26 is preferably made of stainless steel which is highly resistive to corrosion by the chemicals, etc. The viscous developer is stored in a polyethylene tank at room temperature, and is pumped by the metering pump through a conventional heatexchanger, not shown, that brings its temperature to approximately 100 F. in this particular process.

The back-up cylinder 27 is normally provided with a A piece of Teflon tape on its periphery to reduce friction of web t at the point. of contact therewith. The web 4, with the viscous developer coated thereon, passes through a developing chamber 28 formed by hollow metal partitions 29 secured to housing 5 and covered by a pivotally mounted door 31, as seen best in FIG. 2. A jet humidifier 32 is mounted in developing chamber 28, and comprises an open tube 33 having a jet 34 therein through which water is sprayed at a temperature of approximately 100 F. The jet-tube humidifier 32 maintains developing chamber 28 at 100 percent relative humidity. The temperature in developing chamber 28 is further maintained at approximately 100 F. by 100 F. water circulating through hollow partitions 29, and this water is later used in the spray Wash following the development. The temperature of developing chamber 23 registers on an indicating thermometer, not shown, and is manually controlled by adjustment of a commercially available mixing valve, not shown, in the water supply line. The water from jet-tube humidifier 32 is collected and used as the supply for the final wash. Close control of the humidity and temperature in developing chamber 28 is very important since it is essential to maintain the wet bulb temperature in chamber 28 at a substantially constant value in order to insure control over the processing cycle iii and achieve reproducible results. This has been accomplished in this processing device by maintaining chamber 28 in a saturated condition, that is at 100 percent relative humidity, and at a temperature of approximately 100 F. The saturated atmosphere prevents cooling of the developer coating by evaporation which would slow down development and give erratic and unreliable results unless the wet bulb temperature is maintained at a substantially constant value. The saturated atmosphere is easy to achieve and control, and since the wet and dry bulb temperatures are the same in such an atmosphere, the operator merely needs to maintain one temperature. Also, the need for costly equipment to maintain chamber 28 at a substantially constant relative humidity value less than 100 percent and at a substantially constant wet bulb temperature is eliminated. The web 4 passes over a fixed roller 35 which changes its direction in developing chamber 255, and then passes around another fixed idler roller 36 mounted ina spray hopper 37.

Mountedin hopper 3'7 above roller 36 isa spray nozzle system 38 directed at an angle of approximately 30 to the surface of Web 4 for obtaining a rapid and uniform removal of the developer from the emulsion surface. The Water, from the spray wash collects at the bottom of hopper 37 and is directed by a conduit 39 as seen in FIG. '2, to some suitable drain, not shown. After Web 4 is washed, it is guided by idler roller 36, and an overdriven roller 41 under a flag or sheet 42 of Saran-coated Fiberglas screen or other flexible, porous material which carries the stop bath. The overdriven roller 41 subjects web 4 toa tensile force for keeping the web taut sothat no part thereof will contact any of the surfaces of chamber 28. The solution drips from a tube onto the top of flag 42 and is carried by 43 travels over a pair of synthane rollers 44, one of which is driven at approximately 25 times the lineal speed of Web 4. The bleach and fix components flow from supply bottles under a gravity head, are metered by conventional rotometers and flow through conventional heat exchanger into a small chamber where they mix through the swirling action of their flow. The homogenous mixture flows to a plastic distributor tube 45 that drips the blix onto the top surface of belt 43. Because the blix is unstable, when the device 3 is shut down it is important that all the mixed blix be thoroughly cleaned out of the mixing chamber and the feed tube 45. The web 4 passes around a pair of idler rollers 46, 47, and asingle tube 48 is mounted above idler roller 46 for flooding it with water, the Water from roller 46 washing off any blix that may get onto the back of v 7 web 4. Theweb 4 passes from idler roller 47 onto 4-stage belt Washer 12 which thoroughly washes the emulsion side of web 4.

The Washer 12 comprises a plurality of idler rollers 49, 51 for guiding web 4- in a looped path, and a plurality of continuous belts 52 of embossed Mylar or any other suitable flexible material carried by rollers 53 andtank 54 through tanks 53, 59,'and 61 from left to right.

as seen i'nlFIG. 1, and then to a drain, not shown. The web 4 as it leaves the last wash belt 52 passes around rollers 62,163 and under a flag 64 of Saran-coated Fiberglas screenthat carries the stabilizing bath. The stabilizerdrop'sfonto the top of flag 64 from a small distributor tube 65 andis carried by gravity down the length of the flag 64. The washed Web 4 is then guided 'by idler rollers 66,67 to the periphery of the chromiumplated brass drying drum 9 which is heated by heatingcoils, not shown, spaced close to the inside surface of drum 9, as is well known. The dried web 4 is then guided by an idler roller 68 onto a take-up core 69, or, if it is desired to increase the peripheral contact of drum 9 with web 4, a pair of idler rollers 71, 72 may be interposed between drum 9 and roller 68.

The invention has been described in detail with particular reference to a preferred embodiment thereof, but it will be understood that variations and modifications can be effected within the spirit andscope of the invention as described hereinabove, and as defined in the appended claims.

We claim:

1. In a web processing device of the type having developing, rinsing, fixingiand washing zones for continuously processing a web successively transported through said zones, the combination comprising: an extrusion hopper mounted adjacent said web in said developing zone through which a viscose developer is extruded in a finite layer onto said Web; a developing chamber in said developing zone through which said web and developer are transported; andmeans for maintaining the atmosphere in said chamber at a substantially constant wet bulb temperature.

2. The invention according to claim 1 wherein said means comprises a humidifier for introducing moisture into said chamber.

3. The invention according to claim 2 wherein said humidifier is adapted to maintain the atmosphere in said chamber at 100 percent relative humidity.

4. The method for the continuous processing of an exposed photosensitive web which is successively transported through developing, rinsing, fixing and washing zones, comprising: extruding a finite layer of viscous developer onto the exposed surface of the web; transporting the web and developer into said developing zone; subjecting the web and layer of developer in said developing zone to an atmosphere maintained at a substantially constant wet bulb temperature "for a predetermined period for developing said web; rinsing the viscous developer from said web as it is transported from said developing ,zone through said rinsing zone; applying a fixing solution to said web as it is transported from said rinsing zone through said fixing zone to dissolve the undeveloped silver halide remaining in the emulsion; and washing said web as it is transported from said fixing zone through said Washing zone.

5. The invention according to claim 4 wherein said atmosphere in said developing zone is maintained at 100 percent relative humidity.

6. The method for the continuous processing of an exposed photosensitive web which is successively transported through developing, rinsing, stop, bleach-fix and washing zones, comprising: extruding a finite layer of viscous developer onto the exposed surface of the web; transporting the Web and developer into said developing zone; subjecting the Web and layer of developer in said developing zone to an atmosphere maintained at a substantially constant wet bulb temperature for a predetermined period for developing said web; rinsing the viscous developer from said web as it is transported from said developing zone through said rinsing zone; applying a stop solution to said web as it is transported from said rinsing zone through said stop zone to stop further development; applying a bleach-fix solution to said web as it is transported from said stop zone through said bleach-fix zone for oxidizing the developed silver in the emulsion to soluble silver salt, dissolving said silver salt and the undeveloped silver halide remaining in the emulsion; and washing said web as it is transported from said bleach-fix zone through said washing zone.

7. The invention according to claim 6 wherein said at mosphere in said developing zone is maintained at 100 percent relative humidity.

References Cited by the Examiner UNITED STATES PATENTS 1,328,505 1/20 Fish 34-13.8 X 1,728,361 9/29 Pifer 96-61 1,751,881 3/30 Pifer 96-61 2,269,169 1/42 Derhoef et a1. 117--34 2,651,245 9/53 Tondreau -89 2,681,294 6/54 Beguin 117---34 2,949,839 8/60 Aronson et a1. 9589 NORTON ANSHER, Primary Examiner. D. B. LOWE, EMIL G. ANDERSON, Examiners. 

1. IN A WEB PROCESSING DEVICE OF THE TYPE HAVING DEVELOPING, RINSING, FIXING AND WASHING ZONES FOR CONTINUOUSLY PROCESSING A WEB SUCCESSIVELY TRANSPORTED THROUGH SAID ZONES, THE COMBINATION COMPRISING: AN EXTRUSION HOPPER MOUNTED ADJACENT SAID WEB IN SAID DEVELOPING ZONE THROUGH WHICH A VISCOSE DEVELOPER IS EXTRUDED IN A FINITE LAYER ONTO SAID WEB; A DEVELOPING CHAMBER IN SAID DEVELOPING ZONE THROUGH WHICH SAID WEB AND DEVELOPER ARE TRANSPORTED; AND MEANS FOR MAINTAINING THE ATMOSPHERE IN SAID CHAMBER AT A SUBSTANTIALLY CONSTANT WET BULB TEMPERATURE. 